CN105102212B - Flexible composite system and method - Google Patents

Flexible composite system and method Download PDF

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Publication number
CN105102212B
CN105102212B CN201480014608.8A CN201480014608A CN105102212B CN 105102212 B CN105102212 B CN 105102212B CN 201480014608 A CN201480014608 A CN 201480014608A CN 105102212 B CN105102212 B CN 105102212B
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CN
China
Prior art keywords
fabric
adhesive
screen cloth
unidirectional
gap
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CN201480014608.8A
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Chinese (zh)
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CN105102212A (en
Inventor
克里斯托弗·迈克尔·艾达姆斯
韦斯利·爱德华·哈特彻尔
基思·乔尔·麦克代尼尔斯
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Dsm Protective Materials Co ltd
Evant Protective Materials Co ltd
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DSM IP Assets BV
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Priority to CN201811627769.0A priority Critical patent/CN109940959A/en
Publication of CN105102212A publication Critical patent/CN105102212A/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B32B27/322—Layered products comprising a layer of synthetic resin comprising polyolefins comprising halogenated polyolefins, e.g. PTFE
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/10—Removing layers, or parts of layers, mechanically or chemically
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/026—Knitted fabric
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/10—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer reinforced with filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0072—Orienting fibers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/08—Reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/38—Meshes, lattices or nets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
    • Y10T442/184—Nonwoven scrim
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
    • Y10T442/184—Nonwoven scrim
    • Y10T442/197—Including a nonwoven fabric which is not a scrim

Abstract

In various embodiments, describe a kind of improved flexible composite, at least one textile fabric, adhesive-bonded fabric or diaphragm it includes at least one screen cloth and in conjunction with the screen cloth, the screen cloth are made of combined at least two unidirectional belts.In various embodiments, unidirectional belt includes multiple parallel fibre bundles, and the fibre bundle includes the monofilament in binder resin.In various embodiments, the fibre bundle is separated by gap, and the gap can be filled by adhesive or non-stick resin.

Description

Flexible composite system and method
Cross reference to related applications
This application claims the U.S. Provisional Patent Application No.61/780 that on March 13rd, 2013 submits, and 821 priority should Patent application is hereby incorporated by reference in its entirety by reference.
Technical field
Present invention relates generally to improved flexible composites, and relate more specifically to comprising unidirectional fiber reinforcement Layer and screen cloth reinforcing material improved flexible composite；And it is related to manufacturing its method.
Background of invention
Flexible composite is widely used in the application for requiring mechanical flexibility and high intensity and weight ratio.Although flexible Composite material can be counted as a special subset of biggish bulk composite material, but they lead in many particular technologies The importance in domain is very significant.
As its name suggests, the two or more constituent materials of composite material combination, to form united material compositions.It is flexible One example of composite material will be the polymer substrate being embedded in row's flexible fiber.
It is contemplated that with flexible composite in many technical fields, from simple consumer products to advanced aerospace Using.It therefore, will be very favorable for quickly and economically producing the system of high quality flexible composite.
Summary of the invention
The various embodiments of the disclosure generally comprise flexible composite, which includes screen cloth strengthening material Material.Composite material includes one or more unidirectional fibre-reinforced layers, and each layer, which all has, is coated with the very thin of adhesive The parallel fibers of ground expansion (these layers are referred to as " one-way tape " (unitape)).According to an aspect of the present invention, it can be used Fibre bundle manufactures thin unidirectional tape layers, which is made of multiple monofilament, and the monofilament and polymer resin composition simultaneously pass through rotation Revolving die head comes by pultrusion, so that monofilament is unfolded and is orientated in parallel with each other.According on the other hand, composite material includes weaving Or the enhancing of nonwoven auxiliary sets screen cloth (laid scrim).Auxiliary screen cloth of setting is by continuous filament yarn with open mesh structure system At the lower enhancing fabric of cost.The auxiliary manufacturing method for setting screen cloth is chemically bound together non-woven yarns, using uniqueness Characteristic enhance screen cloth.Auxiliary screen cloth of setting is a kind of cost-efficient mode that fibre reinforced materials is added to composite material, Especially in the orientation of deflection (30 ° for example, about +/-, +/- 45 °, +/- 60 °), because at the addition of addition one-way tape oblique layer Reason step is skipped and is substituted with prefabricated screen cloth is inserted into.Auxiliary screen cloth of setting can be pre-coated with adhesive, is laminated into advance Support film, or can be sandwiched between unidirectional tape layers when necessary and in place use gluing.
The another embodiment of the disclosure generally comprises the flexible composite of band gap, by two or more layers One-way tape is made, which has adhesive-free and fiberless interval, to form screen cloth.It is manufactured using fibre bundle thin unidirectional Belt, the fibre bundle are made of multiple monofilament, and the monofilament and polymer resin composition simultaneously, by pultrusion, are made by rotating die head Monofilament is obtained to be unfolded and be orientated in parallel with each other.The key feature of the embodiment be constitute one-way tape fiber be unfolded, and And or, the distance between fiber is band gap, so that adhesive-free and fiberless interval are formed between every group of monofilament, , fibre bundle is removed after monofilament has been unfolded, obtains the one-way tape of similar band gap.By by these unidirectional tape layers Two or more come together to form screen cloth.Additional film, diaphragm, fabric, the non-woven fleece of random orientation, orientation Non-woven fleece, screen cloth or coating can be applied to outer surface, or the forming layer in the composite material.
Various embodiments include the enhancing of the non-woven fleece for the random orientation being made of technical fiber or the non-woven fleece of orientation Type, technical fiber be such as, but not limited to UHMWPE (such as ), aramid fiber (such as ), liquid crystal polymer (such as), the carbon fiber of various grades, PBO (such as), nylon, polyester (Rayon), PEN, Nomex and other fire proofing materials, high temperature fiber, steel or other metallic fibers and their combination.These Enhancement layer can by bonding, melting, dipping, extrusion or coating so that reinforcing material and monolithic thin film (PET, nylon, ECTFE, Carbamate etc.), gas-permeable membrane (Teflon, carbamate, micropore etc.), solvent or aqueous based dispersions, weaving or nonwoven Fabric, leather, unidirectional band or the combination of other layers.
In various embodiments, the method that the disclosure covers manufacture flexible composite, which comprises provide At least one scrim layer, and at least one textile fabric, adhesive-bonded fabric and/or membrane layer are integrated at least one described screen cloth On layer.In various embodiments, scrim layer contains at least two unidirectional belt, which also includes multiple parallel fibres Beam is tieed up, which includes the monofilament in binder resin, and wherein fibre bundle is separated by gap.In various embodiments In, scrim layer includes that commercially available weaving or nonwoven enhancing lay screen cloth.In various embodiments, this method further includes walking as follows It is rapid: to add ventilative or air-locked adhesive to fill the gap.
In various embodiments, the method for manufacturing flexible composite include: as follows come produce include fibre The thin unidirectional tape layers of beam are tieed up, the fibre bundle is made of multiple monofilament, and the step is by the monofilament and fluoropolymer resin group Monofilament described in merga pass rotating die head pultrusion, so that the monofilament is unfolded by gap and is orientated in parallel with each other；Passing through will At least two thin unidirectional tape layers combinations are to produce scrim layer；And by least one textile fabric, without woven fabric, and/or Membrane layer is integrated at least one described scrim layer.In various embodiments, this method further includes the steps that removing multifibres, To generate and/or to enhance the gap.In various embodiments, this method further includes following steps: addition is ventilative or not Ventilative adhesive fills the gap.
Brief Description Of Drawings
Fig. 1 shows the fragmentary perspective view for schematically showing the product according to the disclosure, and wherein one-way tape is in both direction Upper orientation, and combined with screen cloth and external surface coating, to form composite material.
Fig. 2 shows the fragmentary perspective views for schematically showing the product according to the disclosure, wherein the one-way tape with gap It is orientated, and is combined with external surface coating in two directions, to form composite material.
Detailed description of the invention
Following description is only various illustrative embodiments, and is not intended to limit the model of the disclosure in any way It encloses, applicability or configuration.More precisely, following description is various embodiments (including best mode) for ease of description Implementation.As it will be evident that, can be to described in these embodiments in the case where not departing from the principle of the disclosure Feature function and arrangement carry out various changes.
As described in more detail herein, the various embodiments of the disclosure generally comprise flexible composite, the flexibility Composite material includes at least one screen cloth reinforcing material.
Table 1 provides definition and the nomenclature of the various pieces that can be used for the disclosure.
Table 1: definition and term abridged table
The flexible composite of screen cloth enhancing
According to various embodiments, present disclose provides a kind of composite materials, and it includes screen cloth reinforcing elements and at least two A unidirectional band has monofilament in band, and all this monofilament are placed in band with scheduled direction, wherein this monofilament is straight Diameter is less than about 60 microns, and wherein one group of neighbouring interval strengthened in monofilament between each monofilament in the following range: Clearance distance between the adjacent and/or monofilament that stacks is to about 300 times of the monofilament full diameter.
According to an aspect of the present invention, fibre bundle can be used and manufacture thin unidirectional tape layers, the fibre bundle is by multiple monofilament Composition, the monofilament and polymer resin composition and by rotating die head come by pultrusion so that monofilament is unfolded and parallel to each other Ground orientation.According on the other hand, composite material includes weaving or nonwoven enhancing is auxiliary sets screen cloth, such as by Saint-Gobain The material of ADFORS production.
In general, auxiliary screen cloth of setting is continuous filament yarn with the lower increasing of cost made of open mesh structure Strong fabric.The auxiliary manufacturing method for setting screen cloth is chemically bound together non-woven yarns, enhances screen cloth using unique characteristic. Auxiliary screen cloth of setting is to a kind of cost-efficient mode of composite material addition fibre reinforced materials, especially in the orientation of deflection Upper (30 ° for example, about +/-, +/- 45 °, +/- 60 °), because of the addition processing step of addition one-way tape oblique layer (bias plies) It is skipped and is substituted with prefabricated screen cloth is inserted into.It is auxiliary set screen cloth can be pre-coated with adhesive, in advance be laminated into support it is thin Film, or can be sandwiched between unidirectional tape layers when necessary and in place use gluing.
Additional film, auxiliary screen cloth, diaphragm, fabric or the coating set can be applied to outer surface, or in the composite wood Forming layer in expecting.
The screen cloth fiber type that can be used for this system includes but is not limited to: nylon, polyester, UHPWPE (Spectra, Dyneema), to aramid fiber (Kevlar, Nomex, Technora, Twaron), liquid crystal polymer (Vectran), polyimides, its His synthetic polymer (PBO, PBI, PIBT, PBZT, PLA, PPTA), metallic fiber, glass fibre or any combination thereof.
Screen cloth feature and benefit include: dimensional stability, tensile strength, resistance to tearing.
Table 2: technical capability and screen cloth characteristic
Screen cloth structure mode
In various embodiments, for the screen cloth structure mould in the various embodiments of the flexible composite of the disclosure Formula includes but is not limited to " shoulder to shoulder " (side-by-side), " up/down " (over/under), " three directions " (tri- Directional), " four directions " (quad-directional) and " compound ", each of these kind is described in detail in the following table 3 In.
Table 3: structural model:
" with gap " (GAPPY) flexible composite
It include one or more unidirectional fibre-reinforced layers according to the composite material of the various embodiments of the disclosure, Each layer all has the parallel fibers being thinly unfolded for being coated with adhesive (these layers are referred to as " one-way tape ").According to one Aspect can be used fibre bundle and manufacture thin unidirectional tape layers, which is made of multiple monofilament, the monofilament and fluoropolymer resin Rotating die head is combined and through by pultrusion, so that monofilament is unfolded and is orientated in parallel with each other.In various embodiments, structure It is unfolded at the fiber of one-way tape, and or, the distance between fiber is " band gap " (" gapped "), so that at every group Between monofilament formed adhesive-free and it is fiberless interval or, remove fibre bundle after monofilament has been unfolded, obtain class Like the one-way tape of band gap.It can be by the way that the two or more of these unidirectional tape layers be come together to form screen cloth.One In a alternative embodiment, make the long filament expansion (overspread) for constituting each fiber, it is single with formation " there is gap " To band.In this embodiment, the distance between long filament is " band gap " so that formed adhesive-free and it is fiberless between Every.
In various embodiments, ventilative or air-locked adhesive can be used to fill gap.
In various embodiments, the disclosure covers the method for manufacture flexible composite, which comprises is provided to A few scrim layer；And at least one textile fabric, adhesive-bonded fabric and/or membrane layer are integrated at least one described scrim layer On.In various embodiments, scrim layer contains at least two unidirectional belt, which also includes multiple parallel fibers Beam, the fibre bundle include the monofilament in binder resin, and wherein fibre bundle is separated by gap.In various embodiments, Scrim layer includes that commercially available weaving or nonwoven enhancing lay screen cloth.In various embodiments, this method further includes following steps: Multifibres is removed from least one unidirectional belt, to generate and/or to enhance the gap.In various embodiments, originally Method further includes following steps: adding ventilative or air-locked adhesive to fill the gap.
In various embodiments, the method for manufacturing flexible composite include: as follows come produce include fibre The thin unidirectional tape layers of beam are tieed up, the fibre bundle is made of multiple monofilament, and the step is by the monofilament and fluoropolymer resin group Monofilament described in merga pass rotating die head pultrusion, so that the monofilament is unfolded by gap and is orientated in parallel with each other；Passing through will At least two thin unidirectional tape layers combinations are to produce scrim layer；And by least one textile fabric, without woven fabric, and/or Membrane layer is integrated at least one described scrim layer.In various embodiments, this method further includes from described at least one The step of multifibres is removed in one-way tape, to generate and/or to enhance the gap.In various embodiments, this method is also wrapped It includes following steps: adding ventilative or air-locked adhesive to fill the gap.
As represented in figure 1, flexible composite 100 includes the screen cloth or tool that (a) contains two or more unidirectional tape layers There is the layer in gap；(b) one or more films, band, diaphragm, fabric or the coating being set on the one or both sides of screen cloth. In the embodiment of figure 1, for example, unidirectional tape layers in two directions (0 °/90 °) orientation, and with screen cloth or other have The layer in gap and the combination of optional external surface coating, to form composite material.
Fig. 2 schematically shows an embodiment of the flexible composite 100 according to the disclosure, wherein having gap One-way tape 30 and 40 in two directions (about 0 °/90 °) orientation, and not only with screen cloth 50 but also with external surface coating 60 and 70 Combination, to form composite material 100.
" with gap " (" Gappy ") flexible composite product mentioned above is useful, because it can be by For gas-permeable membrane application in, this is because adhesive-free/fiber gap.Version of the material than the pantostrat with long filament It is light.In addition, the composite material can have improved drapability and molding compared with the version with long filament pantostrat Property.
In various embodiments, the nothing of additional film, screen cloth, the layer with gap, diaphragm, fabric, random orientation Outer surface, or the forming layer in the composite material can be applied to by spinning object, the non-woven fleece of orientation or coating.
Various embodiments include the enhancing of the non-woven fleece for the random orientation being made of technical fiber or the non-woven fleece of orientation Type, technical fiber be such as, but not limited to UHMWPE (such as,), aromatic polyamides (such as), liquid crystal polymer (such as), the carbon fiber of various grades, PBO (such as), nylon, Polyester (Rayon), PEN, Nomex and other fire proofing materials, high temperature fiber, steel or other metallic fibers and their combination. These enhancement layers can by bonding, melting, dipping, extrusion or coating so that reinforcing material and monolithic thin film (PET, nylon, ECTFE, carbamate etc.), gas-permeable membrane (Teflon, carbamate, micropore etc.), solvent or aqueous based dispersions, weaving Or adhesive-bonded fabric, leather, unidirectional band or the combination of other layers.
According to various embodiments, present disclose provides a kind of products, wherein at least one described unidirectional band is connected It is connected to the product.
In various embodiments, the flexible composite of the disclosure can be trimmed off any position on product, with It provides to rigidity, the control of flexible and elasticity in the desired direction.
In various embodiments of the present disclosure, this system substantially include one or more continuous " roll-to-roll " (" Roll-to-roll ") production method.In various embodiments, this system is effective, inexpensive and useful.
In various embodiments of the present disclosure, by material layer compositions and solidified using pressure and temperature as follows Together, the step or to be the layer that makes to stack pass through one group of heated roll, hot press, heated vacuum press, heated Band press or be stack layer to be placed in vacuum lamination tool and stack layer is made to be heated.In addition it is possible to use external Pressure (such as being provided by autoclave), to improve the pressure being applied on layer.Vacuum lamination tool can be covered with application vacuum It is sealed in the vacuum bag of lamination instrument, to provide pressure.As those skilled in the art will recognize that, other layers for also can be used Pressure method.
It should be noted that some low-surface-energy fiber requirements carry out surface before the coating to be modified, to promote the knot of coating It closes.Exemplary table surface treatment includes flame treatment, corona, plasma and/or chemical treating process.Then, coating process packet Include but be not limited to curtain coating, gap coating, intaglio plate coating, dip coated, blade coating, metering-type stick applies, inverse roller coating, roller coating and squeezes Extrusion cloth.
The method that coating mentioned above is either partially or fully cured includes but is not limited to: hot-rolling, baking oven, vacuum drying oven make It uses up, infrared and/or UV solidification.In an embodiment of system of the present invention, since selected fabric is special to temperature Sensitivity, because then using low-temperature setting adhesive.Such as UWMWPE fabric greater than 300 °F at a temperature of decompose, and suggest Short term sustained temperature extremes is 145 DEG C.In another embodiment, since the coating is firmer and exposes in heated and UV When it is non-degradable, thus use thermosetting property or part resinoid.In another embodiment, it when subsequent combination and connects When closing range request thermoplastic coating, thermoplastic adhesives, such as carbamate are used.If the adhesive in coating process It is only partially cured, then product is fully cured using subsequent curing schedule, subsequent curing method includes hot-rolling, dries Case, vacuum drying oven use light, infrared or UV solidification and/or autoclave.
In the another embodiment of system of the present invention, uncured described in embodiment in front or part is solid The coated fabric changed carries out autoclave cured process.The coated fabric being uncured or partially cured is placed in release liner Between the layer in (for example, comprising fluoropolymer membrane, such as Teflon), then using the layer of peeling layer and air-breather, with And it is sealed in the lamination on the stiffener plate in vacuum bag.Autoclave uses controlled temperature, pressure and vacuum, removes from coating The air and volatile matter of entrainment, and flow through coating and the surface of fabric and whole thickness.
In various embodiments, one-way tape sheet material is with multiple orientation forming layers, so that it is fibre-reinforced to form two directions Sheet material (such as about 0 °/90 ° ,+45 °/- 45 ° ,+30 °/- 30 °) or the fibre-reinforced sheet material in four directions (such as about 0 °/ 90 °/45 °/- 45 °, 0 °/90 °/30 °/- 30 °) or other " customizations " (" custom ") orientation fibre-reinforced segment, can With countless orientation and layer combination.
In various embodiments, before solidification process, by least one plastic foil (such as PET, PEN, nylon, fluorine Polymer, carbamate or other substances) one or both sides of embodiments noted above are laminated to, or be laminated to Between the layer for the embodiment that face is mentioned.In another embodiment, before solidification process, non-impregnated or dipping fabric It is laminated between the one or both sides of earlier embodiments or the layer of embodiments noted above.
In various embodiments, composite material may include by using pigments or dyes distillation the matrix coloured or Diaphragm.
In various embodiments, anti-flammability adhesive or polymer can be used, or fire retardant can be added and arrive it In his combustible matrix or diaphragm, to improve anti-flammability.Anti-flammability or self-extinguishment matrix resin or lamination or associativity can be used Adhesive, such as Lubrizol 88111 are applied in combination using themselves or with flame-retardant additives.Flame-retardant additives Example include: DOW D.E.R.593Brominated Resin, DOW Coming 3Fire Retardant Resin and tool There is the polyurethane resin (such as EMC-85/10A purchased from PDM Neptec ltd.) of antimony trioxide, other certain anti-flammabilitys add Agent is added to be also possible to applicable.Can be used for improving anti-flammability flame-retardant additives include Fyrol FR-2, Fyrol HF-4, Fyrol PNX, 6 Fyrol and SaFRon 7700, other certain flame-retardant additives are also possible to applicable.Anti-flammability and from The property put out feature can be added in fiber, such as by using flame retardant fiber (such as Nomex or Kevlar), ceramics or gold Belong to wire length silk, fire-retardant compound is directly added in fiber manufacture process into fiber formulation, or by with comprising upper Sizing material, polymer or the adhesive of fire-retardant compound or other suitable substances listed by text carry out coated fiber.In the fabrication process, For any weaving or the mesh material fire retardant pretreatment that supplier can be used to provide in laminated material, or anti-flammability is used Compound is coated with and impregnates.
In various embodiments, antimicrobial/antipathogen can be added into composite material, such as pass through introducing One or more antimicrobial reagents on fluoropolymer resin or fabric are added or are coated on, and to the fibre for composite material Dimension, monofilament, line or tow carry out antimicrobial treatment.Typical material includes but is not limited to OXiTitan Antimicrobial, nanometer silver compound, sodium pyrithione, zinc pyrithione 2- fluoroethanol, the bromo- 2- fluoroethane of 1-, benzo miaow Azoles, fleraxacin, Isosorbide-5-Nitrae-butane disulfonic acid disodium salt, 2- (2- pyridyl group) isothiourea N- oxide hydrochloride, quaternary ammonium salt, 2- pyrrole Pyridine mercaptan 1- oxide, compound zinc pyrithione, compound copper pyrithione, pyrithione magnesium, Bispyrithione, pyrithione, The silica gel that ot- cinnamyl bromide-gel (ot-Bromo Cinnam-Gel), KFO ABC are manufactured.Fibers form such as line, tow and monofilament Silver or other metallic nanoparticle subprocessings can be used, or can be via chemical plating or plating, vacuum deposition or with including patina It closes polymer, adhesive or the sizing material coating of object and there is the silver or other metal coatings coated；These coatings can enhance electricity Property and antimicrobial/antipathogen.Antimicrobial/antipathogen material is also possible to suitably.
It will be apparent to those skilled in the art that can in the present invention various modifications and variations can be made without departing from The spirit or scope of the present invention.Therefore, the present invention is directed to cover any remodeling of the disclosure and modification, if they fall in it is appended In the range of claim and its equivalent.
Equally, numerous technical characteristics of the invention and advantage are stated in the foregoing specification, including have detailed description Equipment and/or method structure and function alternative implementation method.The disclosure is not intended to exhaustion only for explanation.For It will be obvious that, various modifications can be carried out, especially by being submitted in principle of the present invention for those skilled in the art Claims expressed by the term extensive general sense indicate maximum magnitude in structure, material, element, In terms of component, shape, size and component arrangement.As long as these various modifications are without departing substantially from the spirit and model of the claim submitted It encloses, then they are contained in this.

Claims (28)

1. the method for manufacturing flexible composite, which comprises
Thin unidirectional belt comprising fibre bundle is produced as follows, the fibre bundle is made of multiple monofilament, The step is by the monofilament and polymer resin composition and by monofilament described in rotating die head pultrusion, so that the monofilament is logical It crosses adhesive-free and fiberless gap is unfolded and is orientated in parallel with each other；
By the way that at least two thin unidirectional belt combinations are produced scrim layer；And
At least one textile fabric, adhesive-bonded fabric, and/or diaphragm are integrated at least one described scrim layer.
2. according to the method described in claim 1, it further includes following steps: from one or more unidirectional belts Multifibres is removed, to enhance the gap.
3. according to the method described in claim 1, it further includes following steps: adding ventilative or air-locked adhesive to fill The gap.
4. according to the method described in claim 1, wherein at least one textile fabric is integrated to the scrim layer.
5. according to the method described in claim 1, the adhesive-bonded fabric of wherein at least one orientation is integrated to the scrim layer.
6. according to the method described in claim 1, the random adhesive-bonded fabric of wherein at least one is integrated to the scrim layer.
7. according to the method described in claim 1, wherein at least one diaphragm or film are integrated to the scrim layer.
8. according to the method described in claim 1, one of textile fabric is bonded at least one described scrim layer and extremely Between a few unidirectional belt.
9. according to the method described in claim 1, one of diaphragm is bonded at least one scrim layer and at least one list Between the belt in direction.
10. method according to claim 1 or 8, wherein the textile fabric is any one following: knitted fabric, side Shape fabric, the flat mesh fabric in side and ulotrichy fabric.
11. method according to claim 1 or 8, wherein the textile fabric is warp-knitted fabric.
12. according to the method described in claim 1, wherein adding at least one plastic foil to the flexible composite.
13. according to the method for claim 12, wherein the plastic foil is any one following: PET, PEN, nylon, Fluoropolymer and carbamate.
14. according to the method for claim 12, two of them plastic foil is laminated to the two sides of the flexible composite.
15. according to the method for claim 12, wherein the plastic foil (a) be arranged on unidirectional belt it Between, or (b) be arranged between the textile fabric, adhesive-bonded fabric or diaphragm and the scrim layer.
16. according to the method described in claim 1, the non-impregnated fabric (a) of wherein at least one be laminated to it is described flexible multiple The one or both sides of condensation material (b) are arranged between unidirectional belt, or (c) are arranged at described knit Between object, adhesive-bonded fabric or diaphragm and the scrim layer.
17. the method for manufacturing flexible composite, which comprises
At least two unidirectional belts with gap are generated, wherein the gap passes through adhesive-free and fiberless interval It is formed, described at least two unidirectional belts with gap is then combined together to form screen cloth；
Wherein unidirectional belt includes multiple parallel fibre bundles, and the fibre bundle includes the list in binder resin Silk, and wherein the fibre bundle is separated by gap, screen cloth described in wherein at least one and at least one textile fabric knot It closes.
18. according to the method for claim 17, wherein at least one described screen cloth and at least one random or orientation nothing Textile fabric combines.
19. according to the method for claim 17, wherein at least one described screen cloth is in conjunction at least one diaphragm or film.
20. according to the method for claim 17, one of adhesive-bonded fabric be bonded between two screen cloths or Between unidirectional belt inside the screen cloth.
21. according to the method for claim 17, one of textile fabric be bonded between two screen cloths or Between unidirectional belt inside the screen cloth.
22. according to the method for claim 17, one of diaphragm is bonded between two screen cloths or described Between unidirectional belt inside screen cloth.
23. according to the method for claim 17, wherein the gap is ventilative or air-locked viscous by least partly filling Mixture.
24. method described in any one of 7-19 according to claim 1 further comprises adding to the flexible composite At least one plastic foil.
25. according to the method for claim 24, wherein the plastic foil is any one following: PET, PEN, nylon, Fluoropolymer and carbamate.
26. according to the method for claim 24, two of them plastic foil is laminated to the two sides of the flexible composite.
27. according to the method for claim 24, wherein the plastic foil (a) be arranged on unidirectional belt it Between, or (b) be arranged between the textile fabric, adhesive-bonded fabric or diaphragm and the screen cloth.
28. method described in any one of 7-19 according to claim 1 also includes at least one non-impregnated fabric, institute The one or both sides that non-impregnated fabric (a) is laminated to the flexible composite are stated, (b) are arranged at described unidirectional Between belt, or (c) it is arranged between the textile fabric, adhesive-bonded fabric or diaphragm and the screen cloth.
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